U.S. patent application number 11/742208 was filed with the patent office on 2008-10-30 for servicing arrangement for a portable air compressor/generator.
This patent application is currently assigned to Illinois Tool Works Inc.. Invention is credited to Joseph N. Helf, Nathan J. Jochman, John P. Laitala, John C. Leisner.
Application Number | 20080264918 11/742208 |
Document ID | / |
Family ID | 39720402 |
Filed Date | 2008-10-30 |
United States Patent
Application |
20080264918 |
Kind Code |
A1 |
Helf; Joseph N. ; et
al. |
October 30, 2008 |
SERVICING ARRANGEMENT FOR A PORTABLE AIR COMPRESSOR/GENERATOR
Abstract
A system, in one embodiment, may include an engine, a compressor
coupled to the engine, and an oil fill assembly coupled to the
compressor. The oil fill assembly relocates an oil fill location
from a bottom region of the compressor to a top region of the
compressor. A system, in other embodiments, may include a
compressor retrofit kit. The kit may include a first tube
configured to couple with a drain or an existing oil fill disposed
in a base region of a compressor. The kit also may include a second
tube coupled to the first tube, wherein the second tube is
configured to couple with a vent in the compressor. The kit may
include a relocated oil fill section coupled to the first tube, the
second tube, or a combination thereof. A system having a compressor
retrofit kit attached to the case of the compressor is also
provided.
Inventors: |
Helf; Joseph N.; (Appleton,
WI) ; Jochman; Nathan J.; (Appleton, WI) ;
Laitala; John P.; (Appleton, WI) ; Leisner; John
C.; (Appleton, WI) |
Correspondence
Address: |
FLETCHER YODER (ILLINOIS TOOL WORKS INC.)
P.O. BOX 692289
HOUSTON
TX
77269-2289
US
|
Assignee: |
Illinois Tool Works Inc.
Glenview
IL
|
Family ID: |
39720402 |
Appl. No.: |
11/742208 |
Filed: |
April 30, 2007 |
Current U.S.
Class: |
219/133 |
Current CPC
Class: |
B23K 9/32 20130101; F04C
29/02 20130101; F04C 23/00 20130101 |
Class at
Publication: |
219/133 |
International
Class: |
B23K 9/095 20060101
B23K009/095 |
Claims
1. A system, comprising: an engine; a compressor coupled to the
engine; and an oil fill assembly coupled to the compressor, wherein
the oil fill assembly relocates an oil fill location from a bottom
region of the compressor to a top region of the compressor.
2. The system of claim 1, wherein the compressor comprises a rotary
screw compressor.
3. The system of claim 1, wherein the oil fill assembly comprises a
first tube coupled to an oil drain of the compressor.
4. The system of claim 3, wherein the oil fill assembly comprises a
second tube coupled to a case of the compressor.
5. The system of claim 1, wherein the oil fill assembly is coupled
to a base oil fill receptacle of the compressor.
6. The system of claim 1, wherein a bottom region of the compressor
comprises a first oil fill receptacle, and the top region of the
compressor comprises a second oil fill receptacle provided by the
oil fill assembly.
7. The system of claim 1, wherein the oil fill assembly comprises a
tube having a first portion coupled to the bottom region of the
compressor a second portion having an oil fill receptacle, wherein
the oil fill receptacle is disposed adjacent an access panel.
8. The system of claim 1, comprising a generator coupled to the
engine.
9. The system of claim 1, comprising a control panel coupled to the
generator, the engine, and the air compressor, wherein the control
panel includes a welding control feature and an air compressor
control feature.
10. A system, comprising: a compressor retrofit kit, comprising: a
first tube configured to couple with a drain or an existing oil
fill disposed in a base region of a compressor; a second tube
coupled to the first tube, wherein the second tube is configured to
couple with a vent in the compressor; and a relocated oil fill
section coupled to the first tube, the second tube, or a
combination thereof.
11. The system of claim 10, comprising a third tube coupled to the
first tube, wherein the third tube comprises a relocated oil
drain.
12. The system of claim 10, wherein the first tube extends at least
substantially the height of the compressor.
13. The system of claim 10, wherein the compressor retrofit kit is
configured to position the relocated oil fill section adjacent an
access panel.
14. The system of claim 10, comprising the compressor coupled to
the compressor retrofit kit.
15. The system of claim 14, wherein the compressor comprises a
rotary screw compressor.
16. The system of claim 14, comprising an engine coupled to the
compressor, a welding generator coupled to the engine, and a single
chassis supporting the engine, the welding generator, and the
compressor.
17. A system, comprising: a portable unit, comprising: an enclosure
having a top access panel; a compressor disposed within the
enclosure, wherein the compressor comprises an oil drain and an oil
fill disposed in a bottom region of the compressor; and an oil fill
tube comprising a first end coupled to the oil drain and a second
end disposed near the top access panel, wherein the second end
comprises a relocated oil fill.
18. The system of claim 17, comprising a compressor vent tube
coupled to the oil fill tube.
19. The system of claim 17, wherein the portable unit comprises an
engine drivingly coupled to the compressor and a welding generator
in an intermediate position between the compressor and the welding
generator.
20. The system of claim 17, wherein the compressor comprises a
rotary screw compressor.
21. A system, comprising: a compressor retrofit kit, comprising: a
tube configured to couple to a case of the compressor, wherein the
tube allows pressure to vent from the case of the compressor and
the tube relocates an oil fill location from a bottom region of the
compressor to a top region of the compressor.
22. The system of claim 21, comprising a cap and dipstick assembly
configured to couple to the tube.
23. The system of claim 21, wherein the tube extends at least
substantially the height of the case of the compressor.
24. The system of claim 21, wherein the compressor retrofit kit is
configured to position the oil fill location adjacent an access
panel.
25. The system of claim 21, wherein the compressor comprises a
rotary screw compressor.
Description
BACKGROUND
[0001] The invention relates generally to welding systems and more
particularly to welding systems utilizing an engine coupled to an
air compressor and welding generator in a single unit.
[0002] Welding systems generally use an electrical current (e.g.,
welding current) to perform welding. The electrical current may be
provided by an electrical power source (such as a power grid or
battery) or an electrical generator coupled to a mechanical power
source. Examples of mechanical power sources include engines that
output power via a rotating drive shaft. Typically, the drive shaft
is coupled to other devices that consume the energy provided by the
rotating drive. For instance, welding systems often include
internal combustion engines (such as gas or diesel engines) and an
alternator or generator configured to convert the mechanical energy
generated by the engine into electrical energy (e.g., electrical
current). These systems are often referred to as engine-driven
welding generators. An advantage of an engine-driven system is the
potential portability of the system. For instance, welding systems
that employ a generator coupled to an engine are typically
configured as standalone units that do not have connections to a
supplemental power source, such as a power grid. This may be useful
for systems that are traditionally operated at remote
worksites.
[0003] In addition to needing a source of welding current at a
worksite, welding operators often desire other outputs to more
efficiently complete a job. For example, a welding operator may
also use compressed air to operate plasma cutters, air tools and
the like. Typically, compressed air is provided via a standalone
air supply. Thus, a welding operator may use, both, a standalone
engine-driven welding generator and a standalone air supply. The
independence of the two units may increase the amount of time and
labor involved with setup, transportation, and so forth. In
addition, the independence of the two units may result in an
increased amount of maintenance and repair costs due to duplication
of parts.
BRIEF DESCRIPTION
[0004] A system, in one embodiment, may include an engine, a
compressor coupled to the engine, and an oil fill assembly coupled
to the compressor. The oil fill assembly relocates an oil fill
location from a bottom region of the compressor to a top region of
the compressor. A system, in another embodiment, may include a
compressor retrofit kit. The kit may include a first tube
configured to couple with a drain or an existing oil fill disposed
in a base region of a compressor. The kit also may include a second
tube coupled to the first tube, wherein the second tube is
configured to couple with a vent in the compressor. The kit may
further include a relocated oil fill section coupled to the first
tube, the second tube, or a combination thereof. In an alternative
embodiment, a system may include a compressor retrofit kit that may
include a tube configured to couple to a case of the compressor.
The tube allows pressure to vent from the case of the compressor
and relocates an oil fill location from a bottom region of the
compressor to a top region of the compressor.
DRAWINGS
[0005] These and other features, aspects, and advantages of the
present invention will become better understood when the following
detailed description is read with reference to the accompanying
drawings in which like characters represent like parts throughout
the drawings, wherein:
[0006] FIG. 1 is a partial perspective view of an exemplary
engine-driven welding generator/compressor system, wherein two top
access panels are rotated to open positions and a side access panel
is removed to reveal various internal features in accordance with
embodiments of the present invention;
[0007] FIG. 2 is another partial perspective view of the welding
generator/compressor system as illustrated in FIG. 1, wherein an
entire top access panel assembly is removed to further illustrate
various internal features in accordance with embodiments of the
present invention;
[0008] FIG. 3 is a side view of the welding generator/compressor
system as illustrated in FIG. 1, wherein the two top access panels
are rotated to closed positions and the side access panel is
removed to further illustrate various internal features in
accordance with embodiments of the present invention;
[0009] FIG. 4 is a perspective view of an embodiment of an oil fill
assembly coupled to an air compressor of the welding
generator/compressor system as illustrated in FIGS. 1-3;
[0010] FIG. 5 is a side view of an embodiment of the oil fill
assembly coupled to the compressor as illustrated in FIG. 4;
and
[0011] FIG. 6 is a cross-sectional view of an embodiment of the oil
fill assembly coupled to the compressor as illustrated in FIG. 5;
and
[0012] FIG. 7 is a perspective view of an alternative embodiment of
an oil fill assembly coupled to an air compressor of the welding
generator/compressor system as illustrated in FIGS. 1-3.
DETAILED DESCRIPTION
[0013] Referring now to the drawings, FIGS. 1-3 illustrate an
engine-driven welding generator/compressor system 10 having an
engine 12 drivingly coupled to a welding generator 14 and an air
compressor 16 in a single enclosure 18 in accordance with an
exemplary embodiment of the present technique. FIG. 1 is a partial
perspective view of the system 10 with side access panels removed
and top access panels or hatches rotated to open positions. FIG. 2
is another partial perspective view of the system 10 as illustrated
in FIG. 1, wherein the entire top access panel assembly is removed
to provide a better view of the internal features of the system 10.
FIG. 3 is a side view of the system 10 as illustrated in FIGS. 1
and 2. As depicted, the system 10 is configured to provide multiple
outputs, including welding current, alternating current (AC) power,
and compressed air.
[0014] As discussed in detail below, the illustrated system
includes a variety of features to improve serviceability,
reliability, controllability, and integration of the air compressor
16 within the single enclosure 18 of the system 10. For example,
the illustrated system 10 may include a top side oil fill to enable
access at the top of the system 10, rather than a lower or more
inaccessible oil fill location. The illustrated system 10 also may
include unique control features, such as a load priority control
configured to monitor various loads (e.g., generator 14, compressor
16, external loads, etc.) on the engine 12, identify possible
overload conditions, and adjust the various loads based on priority
levels. The control features also may include a specific air
compressor load control, which may be configured to reduce the
engine speed and/or gradually engage (e.g., via an electric clutch)
the air compressor 16 during start up (e.g., a soft start control).
Furthermore, the control features may include a specific air
compressor control regulator, which may be mounted directly on a
control panel (e.g., a front panel) of the system 10 rather than
being in an inaccessible position well within the system 10. The
system 10 also may include a battery and/or a battery charge
system, which may include features to monitor conditions of the
battery (e.g., internal or external to the system 10) and to adjust
the characteristics of the charge (e.g., variable output level,
duration, etc.).
[0015] In certain embodiments, the system 10 may be described as an
air pack welding system (e.g., AIRPAK). The engine 12 provides
output power (e.g., a mechanical output) to drive both the welding
generator 14 and the air compressor 16. In the illustrated
embodiment, the generator 14 is coupled to one side of the engine
12, while the compressor 16 is independently coupled to an opposite
side of the engine 12. Thus, the engine 12 is sandwiched between
the generator 14 and the compressor 16. In addition, the engine 12
may be mounted independently from the compressor 16, such that the
two are mechanically isolated from one another. As discussed in
further detail below, the isolation between the compressor 16 and
the engine 12 may be addressed with a suitable engine-to-compressor
coupling system, such as a geometrically adjustable coupling. The
geometrically adjustable coupling may include a tensioning system
coupled to a belt and pulley system, a special resilient or
spring-like belt, a clutch, or a combination thereof, to provide
some degree of flexibility, positional adjustability, or play.
Thus, the geometrically adjustable coupling is configured to
maintain a connection between the compressor 16 and the engine 12
despite variations in distance, vibrations, and so forth. In other
words, the geometrically adjustable coupling provides a resilient
or distance adjustable connection between the engine 12 and the
compressor 16
[0016] As described below, the power from the engine 12 operates
both the generator 14 and the air compressor 16 via a first shaft
20 and a second shaft 22 (e.g., stub shaft), respectively. In some
embodiments, these shafts 20 and 22 may be independent from one
another, while in other embodiments shafts 20 and 22 may be part of
a single shaft extending through the engine 12. As illustrated, the
shafts 20 and 22 extend out of opposite sides of the engine 12.
These shafts 20 and 22 may be directly or indirectly coupled to one
or more driven mechanisms. For example, an indirect coupling may
include a belt and pulley system, a gear system, or a chain and
sprocket system. In the present embodiment, the first shaft 20
couples directly to the generator 14, while the second stub shaft
22 couples indirectly to the compressor 16. However, either
arrangement can be used for the connection between the engine 12
and the generator 14 and/or the compressor 16.
[0017] For example, as will be discussed in greater detail below,
the engine 12 is coupled to the compressor 16 via a belt and pulley
system including the stub shaft 22, a pulley 24 coupled to the
shaft 22, a compressor drive shaft 26 coupled to the compressor 16,
a compressor pulley 28 coupled to the shaft 26, and a drive belt 30
extending about the pulleys 24 and 28. Therefore, the engine 12 is
capable of providing power to the generator 14 and the air
compressor 16 simultaneously. In the illustrated embodiment, the
engine 12 rotates the stub shaft 22 to transmit rotation and torque
via the pulleys 24 and 28, drive belt 30, and clutch to the
compressor drive shaft 26 coupled to the air compressor 16.
Accordingly, the mechanical energy generated by the engine 12
operates the air compressor 16. As discussed in detail below, in
certain embodiments, the air compressor 16 includes a rotary screw
compressor. Thus, the air compressor 16 and the system 10 may be
capable of continuously providing large volumes of compressed air
16 to a desired application, such as a welding application, without
any need for an intermediate storage tank.
[0018] The engine 12 includes a power source configured to provide
power to the generator 14 and the air compressor 16. In an
embodiment, the engine 12 may include a combustion engine powered
by gas, diesel, LP fuel, natural gas, or other fuel and driving one
or more drive shafts, e.g., 20 and 22. For example, the engine 12
may include an industrial gas/diesel engine configured to output
anywhere from about 24 horsepower (Hp) to about 64 Hp. Generally,
the weight of such an engine 12 may vary with the size and Hp
rating of the engine. For example, a 64 Hp engine may weigh
approximately 1900 lbs., whereas a similar 24 Hp engine may weigh
less than approximately 1000 lbs. Thus, the portable system 10 may
benefit from the use of a smaller engine 12.
[0019] As discussed previously, embodiments may include a generator
14 coupled to the engine 12. Thus, the generator 14 may convert the
power output (e.g., mechanical energy) of the engine 12 to an
electrical power. Generally, the generator 14 includes a device
configured to convert a rotating magnetic field into an electrical
current (e.g., AC generator). The generator 14 includes a rotor
(rotating portion of the generator) and a stator (the stationary
portion of the generator). For example, the rotor of the generator
14 may include the rotating drive shaft 20 disposed in a single
stator configured to create an electrical current (e.g., welding
current) from the rotation of the magnetic field. In an embodiment,
the generator may include a four-pole rotor and three-phase weld
output configured to provide beneficial welding characteristics.
Further, the generator 14 may include a plurality of independent
winding sections in the rotors and/or stators, such that the
generator 14 is configured to output multiple electrical outputs
having different characteristics. For example, the generator 14 may
include a first section configured to drive a welding current to a
welder and a second section configured to drive a current for other
AC outputs. As suggested above, multiple generators 14 may be
connected to the drive shaft 20 or stub shaft 22.
[0020] Also coupled to the engine 12, the air compressor 16 may
provide a continuous source of compressed air for use in plasma
cutting, pneumatic tools, inflating a tire, blowing-off/cleaning a
work piece, and the like. For example, a welding operator may use
compressed air as a high speed gas ejected from the nozzle of a
plasma torch, or may use compressed air to operate tools, such as
pneumatic impact wrenches, spray guns, saws, nail guns, screw
drivers, drills, lifts, and chisels. In the illustrated embodiment,
the air compressor 16 may be described as a continuous air supply
compressor, an indirect mount air compressor, or both. For example,
certain embodiments of the system 10 use a type of the compressor
16 that is not a piston-type air compressor mounted directly to the
engine 12. In an embodiment, the air compressor 16 may include a
rotary screw compressor or another suitable compressor 16
configured to supply a continuous flow of compressed air without
the need for an intermediate storage tank.
[0021] Rotary screw compressors may include a type of gas
compressor that has a rotary type positive displacement mechanism.
The rotary screw compressor typically includes one or more screws,
which rotate within an enclosure to gradually shrink a series of
passages defined by threads of the screws and the surrounding
enclosure. For example, the rotary screw compressor may include a
plurality (e.g., pair) of counter rotating screws, which intermesh
with one another to progressively reduce air volumes between the
intermeshed threads (e.g., a series of shrinking volumes of air).
For example, air is drawn in through an inlet port in the
enclosure, the gas is captured in a cavity, the gas is compressed
as the cavity reduces in volume, and the gas is finally discharged
through another port in the enclosure. The design of a rotary screw
air compressor 16 generally provides for high volumes of compressed
gas in a continuous manner without the need for an intermediate
storage tank.
[0022] Accordingly, the rotary screw air compressor 16 may provide
a direct supply of compressed air on-demand to a desired
application. For example, a plasma cutter may consume air directly
from the unit without the air being compressed into a tank, as
generally done by piston-driven air compressors. However, an
embodiment including a rotary screw air compressor 16 may include
an air tank configured to store the compressed air. For example, a
user may want to generate air for a given period and store the
compressed air for a later use.
[0023] Further, the rotary screw air compressor 16 may be
configured to operate at high speeds and, thus, may use less
gearing and space to couple the rotary screw air compressor 16 to
the engine 12. For example, in an embodiment, the system 10 may
include a rotary screw air compressor 16 operating at speed near
the engine speed, such as 4000 rpm. Thus, the pulley 24 and the
compressor pulley 18 may include similar 1 to 1 ratios and not use
a significantly larger compressor pulley 28 to step down the engine
speed to accommodate the air compressor 16.
[0024] The system 10 may also have an oil fill assembly 31 that
enables a user to perform regular maintenance on the air compressor
16. For example, as depicted, the oil fill assembly 31 may include
a configuration to provide improved access to components of the air
compressor 16 that may otherwise be obscured by other devices
within the system 10. Accordingly a user may easily check and add
fluids to the air compressor 16. For example, the oil fill assembly
31 may be described as an extension, add-on, or retrofit system
configured to relocate the oil fill location from well within the
system 10 to a top access location.
[0025] The system 10 may also include control circuitry to
coordinate functions of a plurality of devices. For example, as
depicted in FIGS. 1-3, the system 10 includes control circuitry 32
in the vicinity of a control panel 34. In an embodiment, the
control circuitry 32 may include a processor, memory, and software
code configured to control and or coordinate operation of the
system 10. For example, the control circuitry 32 may monitor and
control the speed and load on the engine 12, the electrical output
and loads on the generator 14, the air output and loads on the
compressor 16, the startup procedures (e.g., soft start of
compressor 16), and/or the like. For example, as mentioned above,
the control circuitry 32 may identify an overload condition in
response to sensed data, and then reduce the output to protect the
system 10. The control circuitry 32 also may reduce the engine
speed, gradually increase the engine speed, and/or gradually engage
a clutch during start up of the compressor 16. The control
circuitry 32 also may automatically adjust the outputs (e.g.,
compressed air output or electrical output) based on default or
user defined priority levels, minimum workout output levels,
maximum output levels, safety features, and so forth. The control
circuitry 32 also may adjust output levels (e.g., compressed air
output or electrical output) based on a particular application,
sensed feedback, and other closed-loop controls. For example, the
control circuitry 32 may gradually decrease an electrical output
for a battery charging procedure based on sensed feedback from the
battery, thereby maximizing the charge without overcharging the
battery.
[0026] As depicted in FIGS. 1-3, the enclosure 18 includes a common
base or frame 36 with various access panels to enable servicing,
repair, and so forth. For example, a pair of side access panels
(removed) is configured to attach to opposite sides of the frame
36. A top 37 of the enclosure 18 includes first and second access
panels or hatches 38 and 39, which are both rotatable between open
and closed positions above the components of the system 10. As
illustrated, the first hatch 38 can rotate open to enable access to
the compressor 16, the oil fill assembly 31, and other features.
The second hatch 39 can rotate open to enable access to the engine
12 and other features. Other panels of the enclosure 18 may also
include access panels. For example, an oil filter access panel 41
may be included on the rear of the enclosure 18, allowing access to
the oil filter of the compressor 16 and/or use of an oil drain
tube.
[0027] As depicted, the control panel 34 is coupled to an end of
the enclosure 18 near the generator 14. The control panel 34 may
include various control inputs, indicators, displays, electrical
outputs, air outputs, and so forth. In an embodiment, a user input
40 may include a knob or button configured for a mode of operation,
an output level or type, etc. For instance, the user input 40 may
include a rotatable dial to select a mode of operation, such as a
DC weld, an AC weld, a battery charge, or an air tool operation.
The control panel 34 may also include various indicators 42 to
provide feedback to the user. For example, the indicator 42 may
include an LCD to display voltage, amperage, air pressure, and the
like. Embodiments of the control panel 34 include any number inputs
and outputs, such as welding methods, air compressor settings, oil
pressure, oil temperature, and system power. Further, the user
inputs 40 and indicators 42 may be electrically coupled to the
control circuitry 32 and enable a user to set and monitor various
parameters within the control circuitry 32 and other devices of the
system 10.
[0028] The illustrated system 10 also includes various external
connections 44. The external connections 44 may include various
outlets and couplers configured to provide access to the electrical
power and the compressed air generated by the system 10. For
example, the illustrated external connections 44 include an AC
power output 46, a DC power output 48, and a compressed air output
50. In an embodiment these outputs 46, 48 and 50 are coupled to
various devices and tools. For example, the AC power output 46 or
the DC power output 48 can be coupled to various welding and
cutting tools 52. As depicted, the welding/cutting tools 52
included a torch 54 coupled to the external connection 44 via a
supply conduit 56. For instance, the welding devices may receive
current from the generator 14 via the external connections 44. In
such an embodiment, the torch 54 may be used to weld or cut a work
piece 58 coupled to the external connections 44 via a work clamp 60
and a cable 62. As will be appreciated, the torch 54 may include
various welding devices, such as a TIG (tungsten inert gas) torch,
a MIG (metal inert gas) gun, or a plasma cutting torch. Similarly,
the system 10 may provide compressed air from the air compressor 16
via the compressed air output 50. For example an air tool 64 may be
coupled to the compressed air output 50 via an air hose 66. The air
hose 66 may exit the system 10 at various other locations;
including the back of the system 10 proximate to the air compressor
16. The air tool 64 may include various pneumatic tools and the
like. In some embodiments, a plasma cutting torch 54 may receive
both AC power and compressed air from the system 10. In another
embodiment, the plasma cutting torch 54 may receive power from an
external unit (e.g., wall outlet AC power) while receiving
compressed air from the air compressor 16 of the system 10.
[0029] As discussed previously, the system 10 may include multiple
components working in cooperation to generate power, compressed
air, and other outputs. For example, in the illustrated embodiment,
a single engine 12 is coupled to the generator 14 and the air
compressor 16. As will be appreciated, mechanical design of such a
system 10 may entail various arrangements of components to provide
an efficient and reliable system 10. For instance, if the
components are not positioned correctly with respect to one
another, then the misalignment may cause premature wear and/or
failure of the system 10 and its components. For example,
misalignment of the stub shaft 22 may reduce the efficiency of the
system and create additional wear on bearings within the air
compressor 16 or the engine 12. Further, each of the components may
have a tendency to vibrate and, thus, increase the wear potential
on surrounding components. Such a vibration may also reduce the
appeal to operators, as the system 10 may not run as quietly and
smoothly as desired. As discussed in further detail below, various
features of the system 10 are configured to align and isolate
components, including the engine 12 and the air compressor 16.
[0030] FIG. 4 depicts a perspective view of a compressor
maintenance system 100 having the oil fill assembly 31 coupled to
the air compressor 16 in accordance with an embodiment of the
present invention. The oil fill assembly 31 includes a tube 102, a
top piece 104, and a cap 106. Advantageously, the oil fill assembly
31 extends, relocates, retrofits, or generally makes remote the oil
fill location, such that a user can easily access, check, and fill
oil into the compressor 16 without any unnecessary searching,
disassembly of the system, or reaching down into the system 10. In
the illustrated embodiment, the tube 102 acts as an extension to
route the top piece 104 with the cap 106 to a top location within
the system 10, as illustrated in FIG. 1. Again, without this oil
fill assembly 31, the user would likely need to reach deep within
the system 10, remove additional panels, e.g., side panels, remove
other parts blocking access, and so forth. Thus, the compressor 16
could not readily be serviced for an oil check, change, or fill. As
a result, a typical user may not routinely check the oil level, add
oil when needed, or change oil when suitable, which could lead to
premature wear, overheating, and damage to the compressor 16.
Again, the oil fill assembly 31 is a significant improvement for
servicing, maintenance, and overall performance of the compressor
16. The performance and life of the compressor 16 could be
drastically impaired with an inaccessible oil fill assembly.
[0031] In the illustrated embodiment, the oil fill assembly 31
includes a T-fitting 108 and an oil drain tube 110. The oil drain
tube 110 may be used to drain oil from the compressor 16 without
completely removing the oil fill assembly 31. The oil fill assembly
31 also includes a vent hose 112. For example, the vent hose 112
may be configured to vent trapped air within the compressor 16
while adding or draining oil. The vent hose 112 is particularly
useful for speeding up the oil filling or draining process, while
also improving the accuracy of measurements taken regarding the
amount of oil in the compressor 16. Given that trapped air can
detrimentally affect readings of the oil level, the vent hose 112
is particularly useful and advantageous over existing oil fill
assemblies.
[0032] The air compressor 16 also includes a base oil fill location
114, which includes a cap 116 threaded onto a base oil fill
receptacle 118. As appreciated, the base location 114 may be
difficult or impossible for a user to locate, much less access and
add oil via the cap 116. In the system 10 as illustrated in FIG. 1,
the fill location 114 may be buried deep within the enclosure 18,
surrounded by other components, and not easily accessible by a
user. In fact, a user may need to remove components in the vicinity
of the fill location 114, which can cause significant delays and
can deter a user from making regular service checks and oil fills.
Again, the oil fill assembly 31 places the top piece 104 and the
cap 106 toward the top of the compressor 16, such that a user does
not need to search or perform any time consuming tasks to check and
fill the oil. Thus, the oil fill assembly 31 is configured to
retrofit an existing compressor 16 having the base oil fill
location 114, such that the location is more accessible to a user
for servicing, maintenance, and so forth.
[0033] In some embodiments, the top piece 104 may extend into the
control panel 34, the first hatch 38, or to another external
portion of the enclosure 18, such that a user can check and fill
the oil without even opening the system 10. Similarly, the drain
tube 110 may extend to the control panel 34, oil filter access
panel 41, or to another external portion of the enclosure 18, such
that a user can drain the oil without even opening the system 10.
The oil fill assembly 31 may be made entirely or substantially from
metal or a suitable corrosion resistant material, which can also
withstand the pressures generated by the compressor 16. In
addition, the metal or other material may be selected with
properties to withstand the vibrations and heat generated by the
compressor 16, the engine 12, and other components in the welding
system 10. In some embodiments, the oil fill assembly 31 may
include a viewing window, such that a user can visually inspect an
oil level within the compressor 16. For example, again, an oil
level inspection window may be disposed on the control panel 34,
the first hatch 38, or another external portion of the enclosure
18. In other embodiments, a viewing window may be included on the
crankcase of the compressor 16.
[0034] The tube 102, the top piece 104, the T-fitting 108, and the
drain tube 110 are connected together through one or more fittings
120, 122, and 124. The fittings 120, 122, and 124 may be
quick-disconnect fittings (e.g., push-to-connect fittings),
threaded fittings, or any other type of fitting and/or connectors
that can withstand the pressures generated by the compressor 16 and
resist corrosion. The oil fill assembly 31 is connected to a base
126 of the compressor 16 through the T-fitting 108. In one
embodiment, the T-fitting 108 may couple to an existing oil drain
128 (or another suitable receptacle) at the base 126 of the
compressor 16. In other embodiments, a hole or other attachment
point 128 may be added to the compressor 16 by modifying the
crankcase 130 of the compressor 16, or the oil fill assembly 31 may
be coupled to the preexisting oil fill location 114. One side of
the T-fitting 108 connects to the tube 102, and the other side
connects to the oil drain tube 110.
[0035] In one embodiment, the oil drain tube 110 may be a curved
tube, which extends upwardly to a raised position 132 with a plug
134 threaded into a receptacle 136. This raised position 132 may
improve user access and serviceability, for example, by enabling a
user to quickly connect a drainage pump to the receptacle 136 to
withdraw the oil within the compressor 16. Alternatively, another
drainage hose may be quickly connected to the receptacle 136, and
pressure may be applied through the top piece 104 to force the oil
out of the compressor 16. In another embodiment, the oil drain tube
110 may a flexible hose, and may extend or be pulled through oil
filter access panel 41 to drain the oil within the compressor 16.
In other embodiments, the oil drain tube 110 may be straight or may
be omitted entirely, and the T-fitting 108 may be capped at that
end. The T-fitting 108 may be coupled to the compressor 16 and the
components of the oil fill assembly 31 through push-to-connect
fittings, threaded fittings, or any other type of fitting and/or
connector that can withstand the pressures generated by the
compressor 16 and resist corrosion.
[0036] The tube 102 connects the T-fitting 108 to the top piece 104
and provides the height desirable to relocate the oil fill to a
more accessible location. The pre-existing oil fill location 114 is
located near the base 126 of the compressor 16 and is difficult to
access when the compressor 16 is included as a part of the welding
system 10. For example, the welding system 10 may be stored or used
in a confined location, such as the back of a truck. The oil fill
assembly 31 and tube 102 are of sufficient length to relocate the
oil fill, so that it is accessible from the top of the welding
system 10 when the free space around the welding system 10 is
limited. Therefore, the length of tube 102 may vary according to
the size of the compressor 16, the size of the enclosure 18 of the
welding system 10, and the attachment point of the oil assembly 31.
As explained below, the tube 102 also contains a dipstick that may
be used to check the oil level in the compressor 16. Similar to the
T-fitting 108, the tube 102 may connect to the other components of
the oil fill assembly 31 through push-to-connect fittings, threaded
fittings, or any other type of fitting and/or connector that can
withstand the pressures generated by the compressor 16 and resist
corrosion.
[0037] The top piece 104 and cap 106 provide the oil fill point for
the oil fill assembly 31. The cap 106 may be designed to be a
tool-less cap, e.g., a knurled cap, so that removal and replacement
of the cap 106 may be performed by an operator without the use of
tools. Alternatively, in some embodiments, the cap 106 may be of a
locking design and may involve unlocking before removal. Removal of
the cap 106 exposes a fill point at the top piece 104 through which
oil may be added to the compressor 16. The top piece 104 and cap
106 may be of a threaded design such that the cap 106 can be
screwed on or off of the top piece 104. In some embodiments, the
cap 106 may have a hole or slot in the threads to release pressure
from the crankcase 130 of the compressor 16 before the threads of
the cap 106 become fully disengaged during removal. Additionally,
in one embodiment, the cap 106 may be attached to a dipstick that
may be used to measure the oil level in the compressor. In some
embodiments, the dipstick may be a separate piece not coupled to
the cap 106, and may involve separate removal after the cap 106 has
been removed. The cap 106 may also include an o-ring seal or other
seal to seal and prevent pressure or oil from escaping between the
top piece 104 and the cap 106 when the compressor 16 is in
operation.
[0038] Turning now to FIG. 5, a side view of the compressor 16 and
oil assembly 31 is shown in accordance with an embodiment of the
present invention. As is more clearly shown in FIG. 5, the vent
hose 112 is coupled to the top piece 104 and to the compressor
crankcase 130. The vent hose 112 is connected to the compressor
crankcase 130 through a fitting 138. In one embodiment, the fitting
138 is threaded onto the top of the crankcase 130 of the compressor
16. In other embodiments, however, the fitting 138 may be a part of
the crankcase 130 of the compressor 16, or may be welded or
otherwise attached to the crankcase 130. The vent hose 112 may
connect to the fitting 138 and the top piece 104 through
push-to-connect fittings, threaded fittings, or any other type of
fitting and/or connector that can withstand the necessary pressures
and resist oil corrosion.
[0039] The vent hose 112 enables air trapped in the crankcase 130
to be vented while an operator is checking the level of the oil in
the compressor 16 or adding oil to the compressor 16. When adding
or filling oil into the compressor 16, air trapped in the crankcase
130 can vent to atmosphere through the vent hose 112 and out of the
top piece 104, thus preventing false oil level readings and/or
erratic oil filling that may be caused by a buildup of air in the
system. The pressure is then equalized at both ends of the oil fill
assembly 31. In one embodiment, the vent hose 112 is made from
clear, hard plastic tubing, but any tubing that can withstand the
pressures generated by the compressor 16 may be used.
[0040] FIG. 6 depicts a cross-section of the oil fill assembly 31
taken along line 6-6 of FIG. 5 in accordance with an embodiment of
the present invention. As can be more clearly seen in FIG. 6, a
dipstick 140 is coupled to the cap 106 of the oil fill assembly 31.
The dipstick 140 may extend through the top piece 104 and down the
tube 102 at a sufficient length to measure the level of oil in the
compressor 16. Additionally, the dipstick 140 may have graduations
or marking based on the oil capacity of the compressor 16 and
indicating various oil levels such as "FULL," "EMPTY," or any other
oil level. For example, when enough oil is contained in the
compressor 16 such that the oil capacity of the compressor 16 is
met, the dipstick 140 should extend into the oil and indicate a
"FULL" reading. If the oil in the compressor 16 is below the
necessary oil capacity of the compressor 16, the dipstick 140 may
indicate a reading somewhere between the "FULL" and "EMPTY"
markings.
[0041] Operation of the oil assembly 31 in accordance with the
embodiment of the invention depicted in FIGS. 1-6 will now be
described. When an operator desires to check the oil level of the
compressor 16, such as for maintenance or to add oil after draining
the oil through oil drain 110, the operator accesses the oil
assembly 31 by opening the access hatch 38 covering the compressor
16 at the end of the enclosure 18, as illustrated in FIG. 1. For
example, the access hatch 38 may be a "flip-top" design as shown in
FIG. 1, enabling the operator to flip open the access hatch 38
without removing the access hatch entirely. Alternatively, in some
embodiments the access hatch 38 may be completely removable. After
the access hatch 38 is removed or rotated to an open position, then
the operator may access the oil fill assembly 31 and may remove the
cap 106.
[0042] As discussed above, the cap 106 may be of a tool-less design
and an operator may remove the cap 106 without tools. In addition,
the cap 106 may include warning labels or other text and/or
markings indicating the conditions when the cap 106 should or
should not be removed. For example, the warning may indicate that
the cap 106 should not be removed when the compressor 16 is
running. Alternatively, as discussed above, the cap 106 may be of a
locking design that prevents opening unless the operator unlocks
the cap 106.
[0043] During maintenance or service, the operator may remove the
cap 106 and dipstick 140 assembly. Alternatively, the cap 106 and
dipstick 140 may be separate components and the dipstick may
require removal after removal of the cap 106. After removing the
cap 106 and dipstick 140, the operator may read the dipstick 140 to
check the oil level in the compressor 16. According to the oil
level indicated on the dipstick 140, the operator may choose to add
more oil to the compressor 16 through the top piece 104 of the oil
assembly 31. After adding oil, the operator may again insert the
cap 106 and dipstick 31 to obtain another reading of the oil level
in the compressor 16. As discussed above, the vent hose 112 enables
air to vent from the crank case 130 as oil is added to the
compressor 16, so the dipstick 140 should more accurately reflect
the level of oil in the compressor 16. After sufficient oil has
been added to the compressor 16, the cap 106 and dipstick 140 may
be replaced on the oil fill assembly 31.
[0044] FIG. 7 depicts a perspective view of an alternative
compressor maintenance system 200 having an oil fill assembly 202
coupled to the air compressor 16 in accordance with an embodiment
of the present invention. The oil fill assembly 202 includes a tube
204 and a cap 206. Similarly to the other embodiments, the oil fill
assembly 202 extends, relocates, retrofits, or generally makes
remote the oil fill location, such that a user can easily access,
check, and fill oil into the compressor 16 without any unnecessary
searching, disassembly of the system, or reaching down into the
system 10. In the illustrated embodiment, the tube 204 acts as an
extension to a top location within the system 10, as illustrated in
FIG. 1. Again, without this oil fill assembly 202, the user would
likely need to reach deep within the system 10, remove additional
panels, e.g., side panels, remove other parts blocking access, and
so forth. Thus, the compressor 16 could not readily be serviced for
an oil check, change, or fill. As a result, a typical user may not
routinely check the oil level, add oil when needed, or change oil
when suitable, which could lead to premature wear, overheating, and
damage to the compressor 16. Again, as discussed above, the oil
fill assembly 202 is a significant improvement for servicing,
maintenance, and overall performance of the compressor 16. The
performance and life of the compressor 16 could be drastically
impaired with an inaccessible oil fill assembly.
[0045] The tube 204 may be coupled to the crankcase 130 through a
hole machined in the crankcase casting. The tube 204 may be made
substantially or entirely from metal, such as steel, or a suitable
corrosion resistant material, which can also withstand the
pressures generated by the compressor 16. The base of the tube 204
may be threaded to allow coupling to the crankcase 130 through a
machined hole. Alternatively, the tube 204 may be welded or
otherwise attached to the crankcase 130. Advantageously, the oil
fill assembly 202 does not require a vent tube or other pressure
vent from the crankcase 130 of the compressor 16. The tube 204 may
have a diameter and cross-sectional area of sufficient size to vent
pressure from the crankcase 130. For example, as oil is added into
the tube 204, pressure may vent from the crankcase 130 up through
the tube 204 as oil is added, thereby eliminating the need for a
separate pressure vent. Additionally, the oil fill assembly 202 may
require less material for manufacture and require less fittings
than other embodiments, such as oil fill assembly 31.
[0046] The cap 206 may be designed to be a tool-less cap, e.g., a
knurled cap, so that removal and replacement of the cap 206 may be
performed by an operator without the use of tools. Alternatively,
in some embodiments, the cap 206 may be of a locking design and may
involve unlocking before removal. Removal of the cap 206 exposes a
fill point at the tube 204 through which oil may be added to the
compressor 16. The top of the tube 204 and cap 206 may be of a
threaded design such that the cap 206 can be screwed on or off of
the top of the tube 204. In some embodiments, the cap 206 may have
a hole or slot in the threads to release pressure from the
crankcase 130 of the compressor 16 before the threads of the cap
206 become fully disengaged during removal. Additionally, in one
embodiment, the cap 206 may be attached to a dipstick, forming a
cap and dipstick assembly that may be used to measure the oil level
in the compressor. In some embodiments, the dipstick may be a
separate piece not coupled to the cap 206, and may involve separate
removal after the cap 206 has been removed. The cap 206 may also
include an o-ring seal or other seal to seal and prevent pressure
or oil from escaping between the top piece 204 and the cap 206 when
the compressor 16 is in operation. In addition, the cap 206 may
include warning labels or other text and/or markings indicating the
conditions when the cap 206 should or should not be removed. For
example, the warning may indicate that the cap 206 should not be
removed when the compressor 16 is running.
[0047] While only certain features of the invention have been
illustrated and described herein, many modifications and changes
will occur to those skilled in the art. It is, therefore, to be
understood that the appended claims are intended to cover all such
modifications and changes as fall within the true spirit of the
invention.
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